U.S. patent number 6,779,677 [Application Number 10/447,761] was granted by the patent office on 2004-08-24 for aluminum receptacle with threaded outsert.
This patent grant is currently assigned to Exal Corporation. Invention is credited to Thomas Chupak.
United States Patent |
6,779,677 |
Chupak |
August 24, 2004 |
**Please see images for:
( Certificate of Correction ) ** |
Aluminum receptacle with threaded outsert
Abstract
An aluminum container is comprised of a base portion, a
substantially vertical wall portion extending upwardly from the
base portion, a transition portion extending from the wall portion,
and a neck portion extending from the transition portion. The neck
portion is tapered and has an upper end having a wall thickness
that is preferably less than the thickness of the wall of the
remainder of the neck portion. The upper end of the neck portion
may also be chamfered. The aluminum container of the present
invention may be combined with a threaded sleeve to form a
receptacle. The sleeve has an outer surface and an inner surface.
The outer surface has threads thereon and the inner surface has a
taper complementary to the taper of the neck portion so as to form
a friction fit with the neck portion. The sleeve may also have a
notch formed in the periphery of its upper outside surface. When
the upper chamfered end of the neck is curled, the neck portion
extends over a top end portion of the sleeve and terminates in the
notch in the sleeve. Methods of manufacturing such a container are
also disclosed.
Inventors: |
Chupak; Thomas (West Middlesex,
PA) |
Assignee: |
Exal Corporation (Youngstown,
OH)
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Family
ID: |
21713854 |
Appl.
No.: |
10/447,761 |
Filed: |
May 29, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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005044 |
Dec 4, 2001 |
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Current U.S.
Class: |
220/288; 215/335;
215/44; 220/319; 220/906 |
Current CPC
Class: |
B65D
1/0207 (20130101); B65D 1/0246 (20130101); B65D
41/08 (20130101); Y10S 220/906 (20130101); Y10T
29/4992 (20150115) |
Current International
Class: |
B65D
41/08 (20060101); B65D 41/04 (20060101); B65D
1/02 (20060101); B65D 004/08 () |
Field of
Search: |
;220/288,906,319,634,229
;215/40,43,44,329,335 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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715378 |
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Aug 1965 |
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CA |
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1129077 |
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May 1962 |
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DE |
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69 03 478 |
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May 1969 |
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DE |
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29293 |
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May 1981 |
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EP |
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0 549 987 |
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Jul 1993 |
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EP |
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1 069 049 |
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Jan 2001 |
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EP |
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1258715 |
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Mar 1961 |
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FR |
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285 612 |
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Feb 1928 |
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GB |
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61 088932 |
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May 1993 |
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JP |
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Primary Examiner: Weaver; Sue A.
Attorney, Agent or Firm: Thorp Reed & Armstrong, LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention of U.S. application Ser. No. 10/005,044 now
abandoned, entitled "ALUMINUM RECEPTACLE WITH THREADED OUTSERT"
filed Dec. 4, 2001 and assigned to the same assignee as the present
invention.
Claims
What is claimed is:
1. An aluminum container, comprising: a base portion; a
substantially vertical wall portion extending upwardly from said
base portion; a transition portion extending from said wall
portion; and a neck portion extending from said transition portion,
wherein said neck portion is tapered along its length with respect
to the wall portion, wherein said neck portion includes an upper
end having a reduced wall thickness relative to the wall thickness
of the remainder of said neck portion, and wherein substantially
the entire length of said upper end is operable to be curled.
2. The container of claim 1 wherein said taper of the neck portion
is approximately one degree.
3. The container of claim 1 wherein said aluminum container is
comprised of pure aluminum.
4. The container of claim 1 wherein said aluminum container is
comprised of an aluminum alloy.
5. The container of claim 1 wherein said transition portion has a
shape selected from the group consisting of a taper, oval, round,
flat and ergonomic.
6. The container of claim 1 wherein the thickness of said wall
portion is approximately 0.7 mm.
7. An aluminum container, comprising: a base portion; a
substantially vertical wall portion extending upwardly from said
base portion; a transition portion extending from said wall
portion; and a neck portion extending from said transition portion,
said neck portion having a tapered outside diameter, said neck
portion having an upper end having a wall thickness that is less
than the thickness of the wall of the remainder of the neck
portion, wherein said neck portion includes an upper end having a
reduced wall thickness relative to the wall thickness of the
remainder of said neck portion and having a chamfer and wherein
substantially the entire length of said upper end is operable to be
curled.
8. The container claim 7 wherein said taper of the neck portion is
approximately one degree and the chamfer is approximately 45
degrees.
9. The container of claim 7 wherein said aluminum container is
comprised of pure aluminum.
10. The container of claim 7 wherein said aluminum container is
comprised of an aluminum alloy.
11. The container of claim 7 wherein said transition portion has a
shape selected from the group consisting of a taper, oval, round,
flat and ergonomic.
12. The container of claim 7 wherein the thickness of said wall
portion is approximately 0.7 mm.
13. An aluminum receptacle, comprising: an aluminum container
having a base portion, a substantially vertical wall portion
extending upwardly from said base portion, a transition portion
extending from said wall portion, and a neck portion extending from
said transition portion, said neck portion being tapered; and a
sleeve carried on said neck portion, said sleeve having an outer
surface and an inner surface, said outer surface having threads
thereon and said inner surface being tapered so as to form a
friction fit with said neck portion, said neck portion including an
upper end having a reduced wall thickness relative to the wall
thickness of the remainder of said neck portion, wherein
substantially the entire length of said upper end is shaped as a
curled edge extending over at least a portion of said sleeve.
14. The receptacle of claim 13 wherein said taper of the neck
portion is approximately one degree.
15. The receptacle of claim 13 wherein said aluminum container is
comprised of pure aluminum.
16. The receptacle of claim 13 wherein said aluminum container is
comprised of an aluminum alloy.
17. The receptacle of claim 13 wherein said transition portion has
a shape selected from the group consisting of a taper, oval, round,
flat and ergonomic.
18. The receptacle of claim 13 wherein the thickness of said wall
portion is approximately 0.7 mm.
19. The receptacle of claim 13 wherein said receptacle is
approximately 70 to 260 mm in height and approximately 35 to 66 in
diameter.
20. The receptacle of claim 13 additionally comprising a cap having
threads for engaging the threads of said sleeve, and wherein said
cap carries a tamper seal at a bottom portion thereof, said tamper
seal connected to said cap by a plurality of break away
members.
21. An aluminum receptacle, comprising: an aluminum container
having a base portion, a substantially vertical wall portion
extending upwardly from said base portion, a transition portion
extending from said wall portion, and a neck portion extending from
said transition portion, said neck portion having a tapered outside
diameter; and a sleeve carried on said neck portion, said sleeve
having an outer surface and an inner surface, said outer surface
having threads thereon and said inner surface, being tapered so as
to form a friction fit with said neck portion, said sleeve having a
notch formed in the periphery of its upper outside surface, said
neck portion including an upper end having a reduced wall thickness
relative to the wall thickness of the remainder of said neck
portion, wherein substantially the entire length of said upper end
is shaped as a curled edge extending over a top end portion of the
sleeve and terminating in said notch in said sleeve.
22. The receptacle of claim 21 wherein said taper of the neck
portion is approximately one degree.
23. The receptacle of claim 21 wherein said aluminum container is
comprised of pure aluminum.
24. The receptacle of claim 21 wherein said aluminum container is
comprised of an aluminum alloy.
25. The receptacle of claim 21 wherein said transition portion has
a shape selected from the group consisting of a taper, oval, round,
flat and ergonomic.
26. The receptacle of claim 21 wherein the thickness of said wall
portion is approximately 0.7 mm.
27. The receptacle of claim 21 wherein said receptacle is
approximately 70 to 260 mm in height and approximately 35 to 66 mm
in diameter.
28. The receptacle of claim 21 additionally comprising a cap having
threads for engaging the threads of said sleeve, and wherein said
cap carries a tamper seal at a bottom portion thereof, said tamper
seal connected to said cap by a plurality of break away
members.
29. A combination, comprising an aluminum container comprising a
base portion, a substantially vertical wall portion extending
upwardly from said base portion, a transition portion extending
from said wall portion, and a tapered neck portion extending from
said transition portion, said neck portion including an upper end
having a reduced wall thickness relative to the wall thickness of
the remainder of said neck portion, wherein substantially the
entire length of said upper end is curled to define a substantially
unbroken profile; and a sleeve carried on said neck portion, said
sleeve having an outer surface and an inner surface, said outer
surface having threads thereon and said inner surface being tapered
so as to form a friction fit with said neck portion.
30. The combination of claim 29 wherein said taper of the neck
portion of said container is approximately one degree.
31. The combination of claim 29 wherein said aluminum container is
comprised of pure aluminum.
32. The combination of claim 29 wherein said aluminum container is
comprised of an aluminum alloy.
33. The combination of claim 29 wherein said transition portion of
said container has a shape selected from the group consisting of a
taper, oval, round, flat and ergonomic.
34. The combination of claim 29 wherein the thickness of said wall
portion of said container is approximately 0.7 mm.
35. The combination of claim 29 wherein said container is
approximately 70 to 260 mm in height and approximately 35 to 66 mm
in diameter.
36. The combination of claim 29 additionally comprising a cap
having threads for engaging the threads of said sleeve, and wherein
said cap carries a tamper seal at a bottom portion thereof, said
tamper seal connected to said cap by a plurality of break away
members.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to aluminum receptacles and, more
particularly, to aluminum receptacles having a threaded neck for
receiving a cap.
2. Description of the Background
It is known in the art to form drawn, or drawn and ironed, cans
from aluminum and steel for use in the packaging of beer, soft
drinks, oil, and other liquids. Most metal cans for beer and
beverages are adapted to be closed with relatively flat lids or
ends which are secured on the cans by double seaming or a similar
process. The lids may have tear strips formed in them and pull tabs
attached to the tear strips to facilitate access to the tear strips
to thereby provide an opening in the lid.
Not all aluminum containers have flat tops. It is known in the art
to use a series of necking dies on an aluminum container to form a
neck on one end of the container. Threads may then be formed in the
neck portion of the container by positioning first and second
thread rolling tools adjacent to inside and outside surfaces,
respectively, of the neck and rotatably moving the tools against
the surface. Threaded aluminum containers have typically been made
from relatively thick metal, i.e., at least 0.020 inches thick. The
material is typically pure aluminum (99.5-99.8% aluminum) which is
relatively soft and permits the forming of threads in the neck.
The insides of aluminum containers are very often provided with a
coating which prevents interaction between the raw aluminum and the
contents of the container. The process of forming threads on the
neck portion of the container may crack and/or dislodge portions of
the coating thereby allowing the contents of the container to come
into contact with raw aluminum. Furthermore, a coating which is
cracked or otherwise damaged may work loose after the container is
filled thereby contaminating the contents of the container.
An improvement over forming the threads directly in the aluminum
container is to secure a sleeve of plastic or other material around
the neck of the aluminum container. Examples of the use of such a
sleeve can be found in U.S. Pat. Nos. 5,713,235 entitled "Method
and Apparatus for Die Necking a Metal Container," 6,010,026
entitled "Assembly of Aluminum Can and Threaded Sleeve," 5,718,352
entitled "Threaded Aluminum Cans and Methods of Manufacture,"
5,778,723 entitled "Method and Apparatus for Necking a Metal
Container and Resultant Container," 6,010,028 entitled "Lightweight
Reclosable Can with Attached Threaded Pour Spout and Methods of
Manufacture," and 5,822,843 entitled "Method of Making
Bottle-Shaped Metal Cans." Very often, to prevent rotation of the
sleeve on the container, small dents, ribs, slots or the like are
provided on the container and/or the sleeve. The sleeve can also be
adhesively bonded to the container to prevent relative rotation.
However, forming of dents, ribs, slots, or the like in the
container may damage the protective coating on the inside of the
container. Therefore, the need exits for a method for securing a
threaded sleeve to the neck of an aluminum container and the
improved container resulting therefrom.
SUMMARY OF THE INVENTION
The present invention is directed to an aluminum container
comprising a base portion, a substantially vertical wall portion
extending upwardly from the base portion, a transition portion
extending from the wall portion, and a neck portion extending from
the transition portion. The neck portion is tapered and has an
upper end having a wall thickness that is preferably less than the
thickness of the wall of the remainder of the neck portion. The
upper end of the neck portion may also be chamfered.
The aluminum container of the present invention may be combined
with a threaded sleeve to form a receptacle. The sleeve has an
outer surface and an inner surface. The outer surface has threads
thereon and the inner surface has a taper complementary to the
taper of the neck portion so as to form a friction fit with the
neck portion. The sleeve may also have a notch formed in the
periphery of its upper outside surface. When the upper chamfered
end of the neck is curled, the neck portion extends over a top end
portion of the sleeve and terminates in the notch in the
sleeve.
The present invention is also directed to a method of affixing a
sleeve to the neck of an aluminum bottle of the type having a
tapered neck and wherein the sleeve has a complementary taper. The
method is comprised of positioning the sleeve onto the neck such
that a portion of the neck extends beyond the sleeve, and curling
the portion of the neck extending beyond the sleeve so that the
curl covers at least a portion of the upper end of the sleeve. The
curling step causes the sleeve to seat on the neck so as to form a
friction fit therewith.
By providing the neck portion of the container with a taper, and
providing the threaded sleeve with a complementary taper, a
friction fit can be obtained without requiring any dimples, dents,
or similar structure in either the neck portion or the threaded
sleeve. Because of the taper, the threaded sleeve can be easily
inserted onto the neck portion of the container. Thereafter, the
curling process (which curls the end of the neck portion extending
beyond the sleeve) pushes the threaded sleeve further down onto the
neck portion of the container thereby causing an extremely tight
friction fit. By controlling the amount of the neck portion which
extends beyond the threaded sleeve, and therefore the amount of
material available for curling, the threaded sleeve can be
precisely positioned on the neck portion of the container.
Additionally, by providing a notch in the upper outside peripheral
surface of the threaded sleeve, the curled edge of the neck portion
may terminate in the notch thereby covering the entire top edge of
the threaded sleeve as well as providing a smooth profile for the
finished receptacle. There is no exposed aluminum, and no
possibility of damaging the protective coating on the inside of the
container. Those, and other advantages and benefits, will become
apparent from the detailed description of the preferred embodiments
hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
For the present invention to be easily understood and readily
practiced, the present invention will now be described, for
purposes of illustration and not limitation, in conjunction with
the following figures, wherein:
FIG. 1 illustrates a container constructed according to the present
invention;
FIG. 2 illustrates the detail of the upper end of the neck portion
of the container;
FIG. 3 illustrates an exemplary necking die;
FIG. 4 is a perspective view of the threaded sleeve;
FIG. 5 is a side view of the threaded sleeve;
FIG. 6 is a top view of the threaded sleeve;
FIG. 7 is a cross-sectional view of the threaded sleeve taken along
the lines VII--VII in FIG. 6;
FIG. 8 illustrates the combination of a container as shown in FIG.
1 carrying a sleeve as shown in FIG. 4;
FIG. 9 illustrates an exemplary curling die;
FIG. 10 illustrates a receptacle formed from the container and
sleeve;
FIG. 11 illustrates the detail of the neck portion carrying the
sleeve;
FIG. 12 illustrates a container not carrying a threaded sleeve; the
container end has been curled to further illustrate the curl;
FIGS. 13-16 illustrate other shapes for the transition portion of
the container/finished receptacle; and
FIG. 17 illustrates a cap.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a container 10 constructed according to the
present invention. The exemplary dimensions illustrated in FIG. 1
are for purposes of illustration and not limitation. All dimension
are in millimeters.
The container 10 is comprised of a base portion 12 from which
extends a substantially vertical wall portion 14. A transition
portion 16 extends from the wall portion 14 and a neck portion 18
extends from the transition portion 16. It is anticipated that the
container 10 may be fabricated using a well known impact extrusion
process. In the impact extrusion process, a slug of substantially
pure aluminum (meaning aluminum having a purity of approximately
99.5-99.8%) is impact extruded to form a container of the desired
diameter and having walls of a given height. After impact
extrusion, the wall portion 16 may be lengthened using one or more
dies. Thereafter, the container is trimmed to remove the uneven
edges.
After trimming, the interior of the container may be coated with a
protective coating of lacquer which is then cured in an oven.
Thereafter, graphics may be applied to the outside of the container
10.
The typical impact extrusion process used to produce, for example,
aerosol containers, is modified after the neck portion 18 has been
formed through the application of a series of necking dies
according to known processes. After the neck portion 18 has been
formed, the final necking die or dies imparts a slight taper to the
neck 18. An exemplary necking die 21 is illustrated in FIG. 3. As
can be seen from the exemplary necking die in FIG. 3, upon
insertion of the container 10, the neck portion 18 is tapered such
that the neck portion is approximately 26.6 millimeters at its
upper end 20 and 27.31 millimeters at its bottom. Although the
taper in the preferred embodiment is approximately 1.degree., it is
anticipated that tapers of other dimensions may be used. The
dimensions shown in FIG. 3 are exemplary only.
After the neck portion 18, has been tapered, a portion of the
material at the upper end 20 thereof is removed so that the upper
end 20 of the neck portion 18 has a wall thickness that is less
than the thickness of the wall of the remainder of the neck portion
18 as illustrated in FIG. 2. In the embodiment shown in FIG. 2,
0.20 mm of material has been removed from the topmost 4 millimeters
of the upper end 20 of the neck portion 18. Additionally, the end
of the neck portion 18 has been chamfered at 45.degree.. Although
the detail shown in FIG. 2 is not necessary to obtain a friction
fit between a threaded sleeve 22 illustrated in FIGS. 4-7 and the
neck portion 18 of the present invention, removal of the material
and chamfering of the edge provide advantages which will be
described herein below.
Turning now to FIGS. 4-7, the threaded sleeve 22 is illustrated. As
seen in FIG. 4, the threaded sleeve 22 has an outer surface 24
carrying threads 26 and an inner surface 28. The inner surface 28
is provided with a taper complementary to the taper on the neck
portion 18 of the container 10. As seen best in FIG. 6, a top edge
29 of the threaded sleeve 22 may have notches 30 which are a
remnant of the process used to manufacture the sleeve 22. The
exemplary dimension illustrated in FIG. 7 are for purposes of
illustration only, and not limitation. The threaded sleeve 22 is
preferably comprised of plastic but may be comprised of a number of
other materials such as aluminum or other metals.
As can be seen in FIGS. 5, 6, and 7, a notch 32 is formed in the
periphery of the upper outer surface 24 and at the top edge 29 of
the sleeve 22. The purpose of the notch 32 is described
hereinbelow.
Turning now to FIG. 8, a container of the type illustrated in FIG.
1 is illustrated carrying a threaded sleeve 22 of the type
illustrated in FIG. 4 on the neck portion 18 of the container 10.
Approximately 2-3 millimeters of the upper end 20 of the neck
portion 18 extends beyond the threaded sleeve 22. The final seating
of the sleeve 22 on the neck portion 18 can be controlled by the
height by which the upper end 20 of the neck portion 18 extends
beyond the threaded sleeve 22 as will be described.
The container illustrated in FIG. 8 is input to a plurality of
curling dies 34, one of which is illustrated in FIG. 9. The
plurality of curling dies 34 is positioned around a centering
mandrill, not shown. The upper end 20 of the container 10 is guided
into the plurality of curling dies 34 through the use of the
centering mandrill. Curling dies 34 cause the material of the upper
end 20 of the neck portion 18 extending beyond the threaded sleeve
22 to be curled as seen in FIGS. 10, 11, and 12. The dimensions
illustrated in FIG. 9 are exemplary only and are not limitations on
the present invention.
Turning now to FIGS. 10, 11, and 12, FIG. 10 illustrates a
completed receptacle 36. As is seen, the completed receptacle 36 is
comprised of the container 10 and the threaded sleeve 22 fastened
thereto. In the present invention, the fastening mechanism is
primarily by means of a friction fit.
As seen in greater detail in FIG. 11, the upper end 20 of the neck
portion 18 is curled so that it completely covers the upper edge 29
of the sleeve 22. Additionally, the curl terminates in the notch 32
formed in threaded sleeve 22. As can be seen in FIG. 11, by virtue
of the reduced thickness of the upper end 20 and the chamfer, the
curl terminates in notch 32 in a manner to provide a substantially
unbroken profile for the top of the receptacle 36. In addition, the
curled portion is covered with lacquer so that there is no exposed
aluminum. Finally, the curl completely covers the top edge 29, and
hence the notches 30, in the top edge 29 of the threaded sleeve 22.
As with the other figures, the dimensions shown in FIG. 11 are
exemplary only and do not limit the scope of the present
invention.
In FIG. 12, a container 10 is illustrated which has been curled
without the threaded sleeve. Thus, FIG. 12 provides an additional
illustration of the curl formed on the upper end 20 of the neck
portion 18. The dimensions shown in FIG. 12 are exemplary only and
are not intended to limit the scope of the present invention.
It is anticipated that the container and resulting receptacle of
the present invention may be formed in a variety of shapes and
sizes. It is anticipated that the container and resulting
receptacle may have a diameter of, for example, 35 mm-66 mm and a
height of, for example, 70 mm-260 mm. The transition portion 16
illustrated in FIG. 1 is referred to as a tapered shoulder. Other
types of transition portions 16 may include a round shoulder as
shown in FIG. 13, an oval shoulder as shown in FIG. 14, an
ergonomic shoulder as shown in FIG. 15, and a flat shoulder as
shown in FIG. 16.
FIG. 17 illustrates a cap 38 which may be used to seal the
receptacle 36 of the present invention. The cap 38 is preferably
formed of aluminum. The cap 38 has at the top thereof a material,
such as PVC, which is intended to act as a liner and create a seal.
The cap 38 is positioned over the threaded sleeve 22 of the
container 36. Thereafter, pressure is applied, for example, a
pressure of 35 inch pounds, in a downward manner to affect the
seal. While the downward pressure is applied, thread rollers apply
side pressure of, for example, 38 inch pounds, to cause the cap 38
to deform to thereby produce threads complementary to the threads
carried by the threaded sleeve 22.
A tamper seal 42 is carried at a bottom edge 44 of the cap 38 by a
plurality of breakaway members 46. As is known in the art, as the
cap 38 is applied to the receptacle 36, the tamper seal 42 is bent
inwardly. The inward bending of the tamper seal causes the tamper
seal to be tucked under, for example, a bottom protrusion 48 of the
threaded sleeve 22 best seen in FIG. 11. With the tamper seal 42
thus positioned, removal of the cap 38 will cause the break away
members 46 to break away from the tamper seal 42 thereby leaving
the tamper seal 42 on the neck of the receptacle while the cap 38
is removed. Cap 38, being threaded, may then be replaced on
receptacle 36 to reseal it. Other types of caps and tamper seals
may be provided. For example, ratchet teeth (not shown) may be
formed on the bottom of threaded sleeve 22 which meet with teeth
held in the tamper seal, which is connected to a cap through break
away members. Rotation of the cap in a clockwise direction allows
the cap to be seated while rotation in a counter-clockwise
direction causes the tamper seal to break away.
While the present invention has been described in conjunction with
preferred embodiments thereof, those of ordinary skill in the art
will recognize that many modifications and variations are possible.
Such modifications and variations fall within the scope of the
present invention which is limited only by the following
claims.
* * * * *